Laminate panel, method for manufacturing a laminate panel and press element to realize the method

Abstract

A method for manufacturing a laminate panel, where in a first step a press element is manufactured showing a surface relief. In a second step by means of the press element a relief is formed in a surface of the laminate panel, where the surface relief of the press element is provided with protrusions, which during pressing form recesses in the surface of the laminate panel. The recesses imitate wood pores. When manufacturing the press element, at least a number of the protrusions is made elongate and as such are formed substantially or essentially by a machining treatment with rotating cutting tools.

The invention claimed is: 
     
       1. A method for manufacturing a laminate panel, comprising the steps:
 where in a first step a press element is manufactured showing a surface relief, and 
 in a second step a relief is formed in a surface of the laminate panel by the press element, 
 wherein said surface relief of the press element is provided with protrusions, which during pressing form recesses in said surface of the laminate panel, said recesses imitating wood pores, 
 wherein when manufacturing the press element, at least a number of said protrusions is made elongate and as such are formed substantially or essentially; 
 wherein the method includes forming said at least a number of said protrusions by the step of a machining treatment with rotating cutting tools; 
 wherein said press element is provided with a structured surface of more than one square meter; 
 wherein said machining treatment with rotating cutting tools is a milling treatment, and in that a post-treatment is performed on the milled surface locally by a laser treatment; 
 wherein said post-treatment is only performed on lower-situated regions which are located between said protrusions formed by said milling treatment, said post-treatment removing height differences between the protrusions along surfaces of the lower-situated regions. 
 
     
     
       2. The method according to  claim 1 , wherein the laminate panel is composed, at least by a press treatment, of a substrate and one or more material sheets, wherein in the same press treatment said press element is applied and the respective recesses are formed in the surface of the laminate panel. 
     
     
       3. The method according to  claim 1 , wherein said surface to be structured is structured in different steps, wherein one or more finishing treatments follow one or more roughing treatments, wherein a quantity of material to be machined per rotation of the cutting tool and/or a diameter of the milling tool is smaller in said finishing treatment than in said roughing treatment. 
     
     
       4. The method according to  claim 1 , wherein said surface to be structured is subdivided into at least two sections having a surface relief which are independent from each other. 
     
     
       5. The method according to  claim 1 , wherein the protrusions are formed with a cross-section having at least one inclined flank, wherein the at least one flank has at least one of a flank portion with an inclination of more than 60° or less than 90°. 
     
     
       6. The method according to  claim 5 , wherein the at least one flank has a maximum depth over which said at least one flank portion extends and is larger than a maximum distance between respective flank portions, measured in transverse direction and parallel to a plane of the laminate panel. 
     
     
       7. The method according to  claim 1 , wherein said surface relief forms more than 50 percent of a respective surface of the press element. 
     
     
       8. The method according to  claim 1 , wherein all of the surfaces of the lower-situated regions are free from height differences as a result of the post-treatment.